CLARKSON KNIFE GATE VALVE MODEL ZP3OO INSTALLATION AND MAINTENANCE INSTRUCTIONS

Transcription

1 Before installation these instructions must be fully read and understood GENERAL INFORMATION The Clarkson ZP300 knife gate valve is designed to meet extremely rugged and challenging requirements of expansible fluid applications in the oil sands processes. Please take note of specific installation tags provided with each ZP300 series valve. 1. Compliance to ASME B16.34 Class 300, Valves-Flanged, Threaded, and Welding End and MSS SP 135 (Long Face-to-Face). 2. Bi-directional valve, no special concerns in relation to direction of flow are required when installing the valve. 3. Mating line flanges must be properly aligned. Slip-on or weld flanges can be used. Never try to make up for misaligned pipe flanges by the line bolting. 4. Flange fasteners should be tightened in a uniform manner using a cross-pattern to prevent distortion of the valve. 5. Pipe supports and/or expansion joints should be used to minimize pipe loads on valves. ZP300 valves are suitable for use in either vertical or horizontal lines. If installation is other than vertical, additional support will be required for cylinder actuated valves. COMPLIANCE LABEL LABEL CONTENTS Item Description Example Product code Manufacturer s model/code KGVS Clarkson 3M28CHX8CZZUCRCC6Z11CAB Part number Manufacturer s pn Serial number Manufacturer s sn Size NPS valve size 28 Class Pressure rating per conforming standard 300 Duty Type of service depending on valve configuration (ext or int mounted flow ring will change duty) EXT FR NOT DE or INT FR DE Ring material Compliance standard for flow ring material 17-4 Service limit Limits in pressure and temperature operation 740psi/100F Conformance Standard used for design and manufacture ASME B16.34, MSS SP-135 Crn Canadian registration number 0C Body material Compliance standard for body material WCB/LCB Gate material Compliance standard for gate material 17-4 Seat material Seat material URET Packing material Packing material TPE/GR Emerson. All Rights Reserved. VCTDS EN 16/12

2 INITIAL INSPECTION FIGURE 1 1. Examine entire valve and report any damage or discrepancies immediately. 2. Accessories, if any, including solenoids, limit switches, positioners, etc., are tested for functionality prior to shipment. Examine carefully for damage which may occur during shipment. 3. Operators: standard manual hand wheels may be shipped loose for field installation. It is necessary to use a pipe wrench or large crescent wrench to properly tighten the hand wheel retaining nut. Be sure to fully tighten. 4. Packing assembly: the packing gland bolts should be checked and adjusted to obtain a first time packing seal. Packing gland nuts may become slightly loose when valve is shipped. Field adjustment is expected and desired. (Figure 1. Tighten just enough to stop any leakage. Overtightening may increase valve operating torque and shorten packing life). OVERALL ENVELOPE DIMENSIONS FOR ZP300 WITH HC ACTUATOR Size NPS A* B C D * Face to face dimensions per MSS SP-135 long pattern BOLTING AND INSTALLATION INSTRUCTIONS ZP300 standard flange configuration is flanged where port flange mounting holes are drilled and tapped. Flange mounting holes in chest area are limited to a depth of 1 x flange bolt diameter. It is recommended that studs be used on all flange mounting holes in chest area. WARNING Care must be taken when installing studs or bolts in tapped flange holes in chest area to prevent damage to internal wall profile. NOTE Optional through bolting configurations are also available. TABLE 1 - MAXIMUM TORQUE ON FLANGE BOLT/STUD Torque Recommended bolt Recommended stud NPS Bolt size (ft lb) length (in) length (in) 3 3/ / / / / / / / / / / / / / ZP300 Series valves are design to suit flanges compliant to ASME B16.5 and B16.47, and gaskets designed to ASME VIII-1 Appendix 2, and ASME B16.20 and B Torque on Flange bolt should not exceed values shown in Table 1. NOTES 1. Maximum torque should not be exceeded to insure threaded flange holes in valve body are not damaged. 2. The recommended bolt length assumes; final gasket Thickness =.125", Min F436 Flatwasher Thickness 1x bolt diameter thread depth, and common heavy hex bolt lengths. Use the below equation to calculate flange bolt length per your application. It is strongly recommended stud to be used to achieve maximum thread engagement length. 2

3 BASIS OF BOLT LENGTH AND STUD LENGTH CALCULATION 1x Bolt dia. Valve body recess (flowring raised face) Gasket thickness.06 Nominal flange raised face A 1x Bolt dia. deep Bolt length Stud oval A Flange thickness Valve body recess Gasket thickness.060 Flange raised face Washer thickness A A Flange thickness (F436) Washer thickness (F436) Is the raised face on the body Is the raised face on the body Nut height (heavy hex) Extra length Bolt length = Washer thickness + Flange thickness + Flange raised face + Gasket thickness + Valve body recess + 1 x Bolt dia GASKET DETAIL ACTUATION HYDRAULIC CYLINDER ACTUATION Gasket ID matched to flow ring ID Gasket Flow ring with overlay ZP300 has two options for actuation: Hydraulic Cylinder (HC) and Bevel Gearbox (BG) with manual hand wheel. The HC option is designed to operate with a hydraulic fluid pressure of < 2000 psi and the BG with a rim-pull of < 80 lb. FIGURE 2 WARNING To minimize stress concentration in flow ring ensure flange gasket ID is matched with flow ring ID as shown in Figure 2. HYDRAULIC CYLINDER SIZE AND REQUIRED FLOW RATE Fluid flow rate (in 3 /sec) NPS HC size Rod size 1 in/s Max (close) 1 in/s Max (open) 3 11/2 5/ /2 5/ / / / / / / / / / / / FIGURE 3 Hydraulic cylinder design and mounting arrangement 3

4 OPERATIONAL CONSIDERATIONS BEVEL GEARBOX ACTUATION 1. All valves should be operated within their design pressure and temperature ranges. Under no circumstances should the valves be operated at conditions outside these parameters. 2. The operator should have an understanding of the effects of opening/closing the valve with regards to its role in the overall piping system. Take caution to ensure that the valve is in good operating condition prior to operating it under pressure. 3. Care should be taken when processes contain hazardous and/or otherwise unstable media to ensure the operator is aware of the specific health and safety risks associated with that medium. 4. Stand clear of any moving parts such as the stem and/or gate assembly when operating, use of gloves is suggested when operating manual valves to minimize the risk of injury. 5. All manual handwheel operated valves are designed for hand input. Do not apply excessive input torque via pipe wrenches, 'cheater bars', or other devices. If a manual handwheel actuated valve is difficult to LOCKOUT DESIGN operate due to torque requirements, it is recommended that the valve be supplied with or converted to a bevel gear, air/ hydraulic cylinder or electric motor actuator. 6. Electric motor actuated valves should be left in their factory set condition unless the system operating parameters dictate a change. If changes are necessary, they should be performed in small increments using the lightest/lowest setting possible to achieve the desired performance and then the valve/actuator function inspected. Excess torque and/or thrust in the motor settings may damage or lockup the valve. 7. The ZP300 valve is position seated and should never be torque seated. Do not use the motor torque settings to seat the valve. 8. Care should be taken to ensure that electrical motors are wired correctly. Incorrect phasing of 3-phase wiring may cause valve/motor damage. BEVEL GEARBOX SELECTION WITH HANDWHEEL NPS BG size BG ratio HW (in) For sizes NPS 26 and above consult sales for detail FIGURE 4 Yoke with bevel gear actuator and manual handwheel Options 1. Cable lockout standard for manual hand wheel. 2. Bevel gear lockout is standard for use on BG actuators. 3. Lockout pin on both open and closed positions standard on hydraulic cylinder actuators 4. Lockout pin style for open and closed positions are optional for MH valves. 5. Energy lockouts for hydraulic cylinder actuators. FIGURE 5 - Lockout design for ZP FIGURE 7 - Lockout design for ZP300-8 Safety 1. Pin-style lockouts will assume potential energy of actuator has been removed through other means and are designed to prevent gate movement caused by line pressure. They are not designed to overcome or resist an energized hydraulic cylinder actuator. 2. Pin-style lockouts positions will be designed to resist unauthorized manual unassisted operation of the valve and prevent gate movement caused by line pressure. 3. Pin style lockouts not available on BG actuated valves. FIGURE 6 - Lockout design for ZP NOTE Lockout design may vary between sizes. All lockouts include a pin to secure lockout in position and lanyard to tie lockout pin to valve body. FIGURE 8 - Lockout design for ZP300-3 NOTE Lockout pin may differ from illustration 4

5 FLOW RING ROTATION An external flow ring can be rotated three times (3 x 90 ) after original installation. Four ASTM A574 steel, zinc plated socket head cap screws (SHCS) are required to position a ring and compress an o-ring gasket that seals the flow ring to the valve body. Sufficient tapped holes are provided in the valve body so that positioning holes are only used once per rotational position of a flow ring. FIGURE 9 Mounting/sealing external flow ring SIZE AND LENGTH OF ASTM A574 ZC PLTD SHCS TO SECURE FLOW RING External flow ring fastener NPS Size (in) Length (in) / / / / / / / / / / / / / / GENERAL MAINTENANCE Emerson recommends that all Clarkson ZP300 series valves be inspected every 60 days. The following points should be examined and corrected as required: WARNING If valve is not in line the gate must be open or partially open to avoid damage to valve and flow ring. 2. Packing gland: check for leaks or worn packing. If leakage is occurring around the packing gland, tighten the packing gland bolts evenly at all points, being careful not to overstress the bolting. (On some valves this will require two wrenches, one to tighten the nut and the other to hold the packing bolt from turning.) If the valve requires repacking, see additional instructions for repacking on page Flow rings: the valve must be out of line to properly examine flow rings. Look for erosion of hard surfacing and base metal. If base metal is exposed under the hard surfacing, ring should be replaced. If no erosion of base metal, ring may be rotated so worn area is moved from wear path to gain additional service life. 4. Resilient seats: examine seat for cracks, cuts, corrosion, erosion or swelling. Evidence of any above defects may justify replacement if seat has recorded evidence of leaking when closed, or condition is assessed by maintenance engineer to be at risk of pending failure. To replace a seat disassembly of valve is required. 5. If possible stroke the valve through the full open and closed position to make sure it is functioning properly. FIGURE 10 Assembly of external flow ring 1. Cylinder rods, rod boots: look for excessive corrosion, bitumen build-up, tears in rod boot, etc. Check rod boot connections. Check for cylinder rod seal blow-by. FIGURE 11 Major components Packing gland 17.4PH gate Packing Gate scraper Flow ring O-ring Body O-ring Polyurethane seat Flow ring Polymer liner (UHMPW-PE) Cast body 5

6 REPACKING INSTRUCTIONS 1. Each packing piece is cut a bit longer to add some compression within each layer and to accommodate for fraying strands of packing at each end. The size, length, and quantity of each piece can be found in the relevant Table. Each layer shall alternate between both the packing width pieces and the position of the smaller end pieces, as shown in Figure 12. Smaller end pieces will always be the piece to deform into remaining cavity. Note: ensure body O-ring remains protruding from packing box after installation of packing. 2. Method of installing packing is shown in Figure 13. Place one end of packing to side of packing box. The other end should touch other packing pieces once installation of packing commences. 3. Start at the hump of each packing piece and pack the packing with a packing tool, as shown in Figure 14. Once the pieces are together to form the first layer, prepacking with a packing tool is required to fill in any gaps that can or cannot be seen. Each layer will require prepacking. Note: do not let packing pieces to twist during installation. 4. Alternate packing layers, as shown in Figures 12 and If packed properly, the smaller pieces should fill in the cavity. Each layer of end pieces should be stacked in a specific way so that a piece of packing is sitting on top of a split line from the previous layer, as shown in Figure 16.To get the smaller pieces to fill in the cavity, opposite sides will have to be compressed to obtain an elongated smaller piece. Note: not all sizes have smaller end pieces; some will have equal size end pieces. 6. Install packing gland with studs, Bellville Washers, and nuts as shown in Figure 17. For initial tightening of packing gland, tighten packing gland to achieve a compression between Use Loctite 262 (Red) on studs to secure in body. Note: ensure each stack is facing the opposite direction and the final stack is cupped downward before adding the nut. 7. Tension must be placed on the nut to prevent the nut from backing out. First stack starts on the bottom, cupped down on the packing gland, as shown in Figure 18. Stacking method is provided on Table 2 FIGURE 12 Installation of packing (ZP shown) Packing width piece Packing end piece Alternating layers Smaller end piece FIGURE 13 Installation of packing (ZP shown) NOTES 1. Stop all small leaks as soon as possible as considerable damage can be done to the valve and the surrounding area if leakage is allowed to continue. 2. Replacement parts including replacement liners, hand wheel and yoke assemblies, gates, packing glands, and packing can be provided from our factory. If valve requires further repair, please contact our office for an estimate of feasibility and cost of repair. Use packing tool for packing, starting at the hump of each piece of packing FIGURE 14 Installation of packing (ZP shown) FIGURE 15 Packing layers alternating (ZP shown) Compress Smaller piece Elongate FIGURE 16 Alternating packing end pieces (ZP shown) TABLE 2 - BELLEVILLE WASHER STACK - Alternative method: regular heavy hex nut Stack NPS 1st 2nd 3rd 4th 5th 6th 7th 8th 9th 3 2 Down 2 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 3 Up 3 Down 1 Up 1 Down 1 Up 1 Down 1 Up 1 Down 6 5 Down 5 Up 5 Down 1 Up 1 Down 1 Up 1 Down 1 Up 1 Down 8 2 Down 2 Up 2 Down 1 Up 1 Down 1 Up 1 Down Down 3 Up 3 Down 1 Up 1 Down 1 Up 1 Down Down 4 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 3 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 7 Up 7 Down 7 Up 1 Down 1 Up 1 Down 1 Up 1 Down 18 7 Down 7 Up 7 Down 7 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 16 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 6 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 8 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 8 Up 8 Down 1 Up 1 Down 1 Up 1 Down 1 Up 1 Down 30 9 Down 9 Up 9 Down 1 Up 1 Down 1 Up 1 Down Down 8 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 7 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 5 Up 1 Down 1 Up 1 Down 1 Up 1 Down Down 10 Up 1 Down 1 Up 1 Down 1 Up 1 Down - - 6

7 FIGURE 17 Installation of Packing Gland (ZP shown) FIGURE 18 Stacking of Belleville Washers (ZP shown) PACKING SIZES No. of Width piece Packing length End piece Length per piece Additional packing Length per piece NPS rows Port dia. Packing size (in) Packing size Qty (in) size Qty (in) ⅜ ⅜ ⅜ ½ ⅜ ½ ⅜ ⅜ ⅜ ⅜ ½ ⅝ ½ ½ ½ ½ ½ ½ ½ ⅝ ½ ½ ½ ½ ⅝ ½ ½ ½ ½ ⅝ ⅝ ½ ⅝ ⅝ ⅝ ⅝ ⅝ ⅝ ⅝ ¾ ⅝ ⅝ ⅝ ⅝ ⅝ ⅝ ¾ ⅝ ⅝ ⅝ ⅝ ⅝ ¾ ⅝ ⅝ ⅝ ¾ ¾ ¾ ¾ ¾ ¾ ⅝ ¾ ¾ ⅝ ¾ ¾ ⅝ ¾ ¾ ½ ¾ ¾ ⅝ ¾ ¾ ⅝ ¾ ¾ ⅝ ¾ ¾ ¾ ¾ ¾ ⅝ ¾ ¾ ¾ x ⅝ ¾ ¾ ¾ ¾ ¾

8 INSTALLATION A Appropriate tie-in capable of supporting load. Turnbuckle for adjustment Saddle style hanger INSTALLATION B Saddle style support Appropriate tie-in capable of supporting load. INSTALLATION C Appropriate tie-in capable of supporting load. Alternate head-support, saddle style preferred Turnbuckle for adjustment HANDWHEEL OR BEVEL GEAR OPERATED VALVES Equipment orientation Valves may be stored in the vertical or horizontal position. Preparation for storage Valves may be stored as shipped, provided the storage facility and equipment orientation instructions above are followed. If valve packaging is altered or removed for receiving inspection, repackage valve as originally received. Standard packaging materials cannot be considered sufficient for outdoor storage. Storage inspection Visual inspection shall be performed on a semiannual basis and results recorded. Inspection as a minimum shall include reviewing the following: Packaging Flange covers Dryness Cleanliness Maintenance Maintenance shall consist of correcting deficiencies noted during inspection. All maintenance shall be recorded. Contact factory prior to performing any maintenance if valve is still covered under warranty. Lubricate as above. Additionally, extend cylinder rod until the valve is fully closed. Coat cylinder rod with high quality heavy grease or synthetic lubricant. Retract cylinder rod until valve is fully open, drawing lubricant into rod end of cylinder. Securely plug cylinder ports with pipe plugs, if cylinder is not prepiped to control accessories. If cylinder is prepiped to accessories, plug all input and output ports of accessories. Storage inspection Visual inspection shall be performed on a semiannual basis and results recorded. Inspection as a minimum shall include reviewing the following: Packaging Flange covers Dryness Cleanliness Maintenance Maintenance shall consist of correcting deficiencies noted during inspection. All maintenance shall be recorded. Contact factory prior to performing any maintenance if valve is still covered under warranty. CYLINDER OPERATED VALVES CYLINDER SUPPORT METHODS FOR HORIZONTALLY OR OFF-VERTICAL MOUNTING Cylinders may require additional support when mounted other than in vertical position. Failure to do so could lead to premature failure of cylinder and/or valve. The following illustrations are suggestions; specific details will have to be determined by customer so support best suits surrounding area. It is important that the cylinder/gate alignment be maintained during valve operation. Supports should be designed to maintain alignment and support bulk of cylinder weight. RECOMMENDED LONG TERM STORAGE The following are recommendations for storage procedures to retain maximum product integrity during long term storage of 1 to 5 years. Storage facility The preferred storage location is a clean, dry protected warehouse. If valves are to be stored outside, precautions should be taken to keep valves clean and dry. Standard packaging materials cannot be considered sufficient for outdoor storage. Equipment orientation The preferred orientation for optimum protection is with the cylinder in the vertical position. This position gives the best support to the cylinder rod and helps reduces the chance of a flat spot developing on the cylinder seals. An acceptable alternate position for valves with cylinder diameters of less than 6 inches (150 mm) is with the cylinder in the horizontal position. Preparation for storage Valves may be stored as shipped, provided the storage facility and equipment orientation instructions above are followed. If valve packaging is altered or removed for receiving inspection, repackage valve as originally received. Standard packaging materials cannot be considered sufficient for outdoor storage. Cylinder storage These cylinder storage instructions are not intended to replace the instructions of the specific cylinder manufacturer and are to be used as a guide only. If specific instructions are required, please contact our office. For storage of up to 3 years; Squirt a high quality grade of hydraulic oil or synthetic lubricant into the cylinder ports and operate cylinder 6-12 times on a yearly basis. For storage 3-5 years; 8